Alternative construction system with architectural elements manufactured with recycled plastic and the formulation of the material thereof

ABSTRACT

The herein application discloses an alternative construction system for buildings, facilities, accessories and products, with architectural elements of easy assembly, manufactured with recycled plastic improved materials, as well as the formulation of the material thereof.

FIELD OF THE INVENTION

The herein invention refers to an alternative construction system forbuildings, facilities, accessories and products, with architecturalelements of easy assembly, manufactured with improved materials made ofrecycled plastic, as well as the formulation of the material thatcomprises said architectural elements.

BACKGROUND

Traditional construction systems such as, clay bricks, concrete bricks,ceramic bricks, concrete panels, steel girders, gypsum, lime, cement,concrete, and wood, have some disadvantages such as that they can beworn with humidity, they are vulnerable to bugs, rodents andmicroorganisms, they can corrode, they propagate fire, they requireadhesive or mortar for their assembly, they have a prolonged assemblytime, a limited useful life, they are expensive and unfriendly with theenvironment.

On the other hand, human activity produces more than 80 million tons ofplastic waste a year worldwide, which accumulates in aquifers and soilsthrough the planet. Said waste can take up to a thousand years to breakdown or decompose.

In this context, recycling activities have been an excellent option foryears to reduce the amount of plastic waste and to reuse them as rawmaterials to manufacture materials and useful objects for dailyactivities, thus minimizing their environmental impact. Therefore, it ismore and more important to obtain recycled materials to manufactureenvironmentally compatible raw materials.

Currently, due to the worldwide economic growth rate, the constructionindustry needs a growing amount of starting materials for its ownoperation, e.g., it is estimated that, on average, more than two tons ofraw material are needed per square meter of building.

In addition, the formulations of the recycled plastic must beappropriate to form a construction element that meets the durability,resistance, and safety demands that are required in the constructionindustry.

In the state of the art, some examples of plastic waste formulationsthat are used as construction materials can be found, e.g., in thedocuments MX 222,419 B, CN 106,280,361 A, and CN 106,243,497 A; however,none of the hereinbefore mentioned documents solve the problem ofproviding alternative construction systems with architectural elementsof easy assembly, manufactured with improved recycled plastic materials,as well as the formulation thereof.

Thus, there is a need to provide architectural elements of easy assemblymanufactured with improved recycled plastic materials to be used inalternative construction systems used to build buildings, facilities,shelters, accessories, and housing products such as dividing walls,window frames, pavers, pillars, fence-posts, tablets, bricks, baffles,blocks, floors, pavements, or any other useful object for construction,as well as the formulation of the improved materials.

SUMMARY

The objective of the herein invention is to provide an alternativebuilding system to build buildings, facilities, shelters, accessories,and housing products such as dividing walls, window frames, pavers,pillars, fence-posts, tablets, bricks, baffles, blocks, floors,pavements, or any other useful object for construction, that consists onarchitectural elements of easy assembly manufactured with recycledplastic improved materials that transform the problem of the plastic'sdegradation time into important features such as resistance anddurability.

Another main embodiment of the herein invention is to provide theformulation of the improved material based on recycled plastic composingthe architectural elements.

A first embodiment of the herein invention consists on a constructionsystem to build buildings, facilities, accessories, and products that donot require maintenance, with architectural elements of easy assembly,manufactured with improved materials based on recycled or recoveredplastic.

A preferred embodiment of the herein invention consists on aconstruction system for buildings, facilities, accessories, andproducts, with architectural elements of easy assembly, manufacturedwith improved materials based on recycled or recovered plastic that doesnot require maintenance, and in addition, they have, a long useful life,resistance to the outdoors, resistance to humidity, immunity to insects,immunity to rodents, immunity to microorganisms; they are anticorrosive,decomposition proof, thermal isolating, acoustic isolating, electricisolating, impact resistant, traction and bending resistant, fireproof,and eco-friendly.

In another embodiment of the herein invention, the construction systemfor buildings, facilities, accessories, and products, with architecturalelements of easy assembly, manufactured with improved materials based onrecycled or recovered plastic that does not require maintenance, has aneasy and fast installation, ease of fabrication, it can be cut, drilled,nailed or pierced, and be plastered, painted, or plated.

In another embodiment of the herein invention, the construction systemfor buildings, facilities, accessories, decoration, and products, witharchitectural elements of easy assembly, manufactured with improvedmaterials based on recycled or recovered plastic that does not requiremaintenance, does not require skilled workforce for its construction.

Particularly, the other main embodiment of the herein invention includesa formulation that comprises the following recycled plastic componentsin different proportions:

-   -   Polyethylene    -   ABS (Acrylonitrile Butadiene Styrene)    -   Calcium Carbonate    -   Polypropylene

In another embodiment of the invention, the components of the recycledplastic of the formulation can also comprise polyvinyl chloride (PVC),polystyrene, polyethylene terephthalate (PET), expanded polystyrene(PS), biaxially oriented polypropylene (BOPP), plastics that can besuitable for the recycling cycle and combinations thereof.

In any of the embodiments of the invention, the assembly may produce lowcost products with prolonged useful life, such as housing buildings,dividing walls, pavers, pillars, fence-posts, tablets, bricks, baffles,window frames, blocks, floors, pavements, or any other useful object forconstruction.

BRIEF DESCRIPTION OF THE FIGURES

The following figures are included to illustrate certain aspects of theherein invention, and they are not exclusive modes. The topic that isdisclosed is capable of modifications, alterations, combinations, andconsiderable equivalents in form and function, as will happen to thoseskilled in the art and that have the benefit of this disclosure.

FIG. 1 illustrates the frontal view of the architectural element ofplastic block that is the main element of the construction system.

FIG. 2 illustrates the right-side perspective view of the architecturalelement of plastic block.

FIG. 3 illustrates the left-side perspective view of the architecturalelement of plastic block.

FIG. 4 shows a right-side perspective view of Jamb 1.

FIG. 5 shows a right-side perspective view of Jamb 2.

FIG. 6 shows a frontal view of the assembly of the architectural elementassemble.

FIG. 7 illustrates a perspective frontal view of a plastic paver.

FIG. 8 illustrates a side view of the paver.

DETAILED DESCRIPTION

According to FIG. 1, the plastic blocks (100) that are main elements forthe construction system, are composed by 4 basic elements that make themassemble in a one-way direction with a male and female system, the malepart consists on the upper (101) and side (102) slip-on connectors, andthe female part consists on the bottom (103) and side (104) wings.

In a preferred embodiment of the invention, the plastic blocks (100) canhave from one to four vertical openings or holes (105) that are used toset electric and hydraulic installations (wiring or tubing) internally,creating a higher quality aesthetic result since they are hidden withinthe construction.

In a non-limiting embodiment of the invention, the male dimensions are0.50 meters (m) (1.64 feet) long, 0.10 m (0.32 feet) high, with aslip-on connector that is 0.03 m (0.098 feet) long, 0.10 m (0.32 feet)high, and 0.03 m (0.098 feet) wide; the female dimensions are 0.47meters (m) (1.54 feet) long, 0.10 m (0.32 feet) high, with a slip-onconnector that is 0.03 m (0.098 feet) long, 0.10 m (0.32 feet) high and0.02 m (0.065 feet) wide.

In another non-limiting embodiment of the invention, the male dimensionsare 0.25 meters (m) (0.82 feet) long, 0.10 m (0.32 feet) high, with aslip-on connector that is 0.03 m (0.098 feet) long, 0.10 m (0.32 feet)high, and 0.03 m (0.098 feet) wide; the female dimensions are 0.22meters (m) (0.72 feet) long, 0.10 m (0.32 feet) high, with a slip-onconnector that is 0.03 m (0.098 feet) long, 0.10 m (0.32 feet) high, and0.02 m (0.065 feet) wide.

In another non-limiting embodiment of the invention, the dimensions ofthe vertical openings or holes (105) are 0.06 (0.19 feet) and/or 0.07 m(0.22 feet) long.

FIGS. 2 and 3 are the left and right side frontal perspectives of theplastic blocks that are easily assembled without mortar, additives,sealants, or adhesives, which eases the wall assembly without the needof qualified workforce, both consist on a male-female system, the malepart consists on the upper (101) and side (102) slip-on connectors, andthe female part consists on the bottom (103) and side (104) wings.

In an embodiment of the invention, the plastic blocks assemble bysliding in one direction, matching the superior (101) and side (102)slip-on connectors of a block with the bottom (103) and side (104) wingsuntil the ends of each block match, to make a male-female contact andfor them to remain assembled without mortar, additives, sealants, oradhesives.

FIG. 4 shows Jamb 1 (200), that is an embodiment of the plastic blockthat is used as a window connector, which rests on the superior slip-onconnector of the blocks and consists on a slot or guide (201), which isalso to connect wall, window, and door openings.

In a non-limiting embodiment of the invention, the dimensions of theJamb 1 (200) are 2.20 m (7.21 feet) long, 0.10 m (0.32 feet) high.

FIG. 5 shows Jamb 2 (300), which is a plastic block embodiment thatworks as a base for the beginning of the construction of a wall, throughits two slots or guides (301 and 301 a) the plastic block must fit usingits lateral sides.

FIG. 6 shows a preferred embodiment to assemble the plastic blocks toform a partition unit joined to a structural column (400).

FIG. 7 illustrates a plastic paver, that is a prefabricated recycledplastic unit with the formulation of the invention, suitable for floorand pavement construction in general, and particularly to constructfloors and pavements for light vehicular and pedestrian traffic.

These units may be smooth or may have different tactile finishes ontheir exposed face, grids, cylinders, guides, lines, and any othergeometric or non-geometric shape.

In a non-limiting mode of the invention, the paving stones havedimensions of 0.40 m (1.31 feet) long, 0.40 m (1.31 feet) wide, and 0.05m (0.16 feet) high.

In another embodiment of the invention, the paving stone is rectangular,circular, triangular, hexagonal, pentagonal, and any and other geometricshape.

FIG. 8 illustrates a preferred mode of a side view of the paver.

The formulation of the architectural elements has as main components thelow-density polyethylene in a laminated and firm form in differentproportions, ABS recovered from technological waste, calcium carbonatecoated with calcium stearate that is included on the formulation as Mesh200, and low density polypropylene in rigid form, these materials areobtained from plastic waste that comes from the group comprising,bottles, trays, packages, covers, lids, and any other plastic objectthat is suitable for recycling.

WORKING EXAMPLES

To provide a better understanding of the herein invention, the followingexamples of certain aspects of some embodiments of the invention areprovided. The following examples are not limitative nor define the wholescope of the invention.

Example 1. Formulation 1 of the Material that Comprises theArchitectural Elements

INITIAL PARTICIPATION PRODUCT TYPE PRESENTATION 36.0% Polyethylene Lowdensity Laminated 16.0% ABS Not Technological waste applicable 18.0%Calcium Coated with Mesh 200 carbonate calcium stearate 6.0%Polyethylene Low density Rigid 24.0% Polypropylene Low density Rigid

Example 2. Formulation 2 of the Material that Comprises theArchitectural Elements

INITIAL PARTICIPATION PRODUCT TYPE PRESENTATION 39.0% Polyethylene Lowdensity Laminated 18.0% ABS Not Technological waste applicable 20.0%Calcium Coated with Mesh 200 carbonate calcium stearate 3.0%Polyethylene Low density Rigid 20.0% Polypropylene Low density Rigid

Example 3. Formulation 3 of the Material that Comprises theArchitectural Elements

INITIAL PARTICIPATION PRODUCT TYPE PRESENTATION 36.96% Polyethylene Lowdensity Laminated 17.39% ABS Not Technological waste applicable 19.57%Calcium Coated with Mesh 200 carbonate calcium stearate 4.35%Polyethylene Low density Rigid 21.74% Polypropylene Low density Rigid

The percentages described in the examples 1, 2, and 3 are defined inweight (% wt.), based on the total weight of the formulation.

As it is used in the herein document, the term “system” refers to thecollection of coordinated elements or parts that constitute the hereininvention. Said collection can allow variations and changes that fitwithin the scope of the herein invention.

As it is used in the herein document, the term “assemble”, “assembly”,or “assembling” or their derivatives, refers to the construction of twoor more plastic blocks by joining and perfectly adjusting the pieces orelements that form it.

As it is used in the herein document, the term “recycle” or “recover”refers to subjecting plastic materials used in one or many occasions toa transformation process or exploitation process so they can be usedagain as architectural elements (plastic blocks).

As it is used in the herein document, the term “improved materials”refers to a plastic block that contains specific amounts ofpolyethylene, ABS, calcium carbonate, and polypropylene.

As it is used in the herein document, the term “initial” refers to thepresentation of the initial plastic materials before they are recycledand turned into architectural elements (plastic blocks).

As it is used in the herein document, the term “architectural elements”refers to a plastic block in a shape as any of the ones described in theherein invention of easy assembly, manufactured with improved materialsmade of recycled plastic that contains specific polyethylene, ABS,calcium carbonate, and polypropylene amounts to be used in alternativesystems for the construction of buildings, facilities, shelters,accessories, and housing products such as dividing walls, pavers,pillars, fence-posts, tablets, bricks, baffles, blocks, floors,pavements, or any other useful object for construction.

Additional Observations

Therefore, the herein invention is well adapted to meet the purposes andbenefits mentioned, as well as those inherent to them. The particularmodes disclosed hereinbefore are merely illustrative, since the hereininvention can be modified and practiced in different but equivalentmanners obvious to those skilled in the art that have the benefit of theteachings of this document. On the other hand, it is not intended tolimit the details of the features provided in the herein document, asidefrom the ones described in the following claims. Thus, it is obviousthat the particular illustrative modes disclosed hereinbefore can bealtered, combined, or modified, and that all those variations areconsidered within the scope and spirit of the herein invention. Theinvention that is disclosed illustratively in this document, can bepracticed appropriately upon the absence of any element that is notspecifically disclosed in the herein document and/or any optionalelement that is disclosed in the herein document. While the formulationsand methods are described in terms of “that comprises”, “that contains”,or “that includes”, different components or steps, the formulations andmethods can also “consist essentially of” or “consist on” the differentcomponents and steps. The numbers and ranges disclosed hereinbefore canvary in some amount. Every time a numerical range with an inferior limitand a superior limit is disclosed, any number and any range includedthat fall into the range are specifically disclosed. The terms of theclaims have their plain and ordinary meaning, unless the contrary isexplicitly and clearly defined by the patentee. In addition, theindefinite articles such as “an” or “a”, as they are used in the claims,are defined in this document to refer to one or more than one of theelements introduced. If there is a conflict with the uses of a word orterm in this descriptive memory, and one or more patents, or otherdocuments that can be added to this document by reference, thedefinitions that are consistent with this description must be adopted.

What is claimed is:
 1. A formulation of recycled plastic comprising: a.polyethylene; b. Acrylonitrile Butadiene Styrene (ABS); c. calciumcarbonate; d. polypropylene, wherein the polyethylene is in an amountwithin the range from 3 to 39% wt, based on the total weight of theformulation; the ABS is in an amount in the range from 16 to 18% wt,based on the total weight of the formulation; the calcium carbonate isin an amount in the range from 18 to 20% wt, regarding the total weightof the formulation; and the polypropylene is in an amount in the rangefrom 20 to 24% wt, based on the total weight of the formulation.
 2. Theformulation of claim 1, wherein an initial polyethylene is in alaminated and rigid form in a different ratio.
 3. The formulation ofclaim 1, wherein an initial ABS is recovered from technological waste.4. The formulation of claim 1, wherein an initial calcium carbonate isincluded on the formulation as a Mesh
 200. 5. The formulation of claim4, wherein the initial calcium carbonate is partially or completelycoated with calcium stearate.
 6. The formulation of claim 1, wherein aninitial polypropylene has a rigid form.
 7. The formulation of claim 1,wherein the polyethylene, ABS, calcium carbonate, and polypropylene areobtained from plastic waste.
 8. The formulation of claim 7, whereinplastic waste is obtained from a group comprising bottles, trays,packages, covers, lids, and any other recyclable plastic object.
 9. Theformulation of claim 1, wherein the amount of polyethylene is 36.96% wt.based on the total weight of the formulation, when in a laminated form.10. The formulation of claim 1, wherein the amount of polyethylene is4.35% wt. based on the total weight of the formulation, when in a rigidform.
 11. The formulation of claim 1, wherein the amount of ABS is17.39% wt. based on the total weight of the formulation.
 12. Theformulation of claim 1, wherein the amount of calcium carbonate is19.57% wt. based on the total weight of the formulation.
 13. Theformulation of claim 1, wherein the amount of polypropylene is 21.74%wt. based on the total weight of the formulation.
 14. The formulation ofclaim 1, wherein the polyethylene is selected from high densitypolyethylene, low density polyethylene, or combinations thereof.
 15. Theformulation of claim 14, wherein the polypropylene is selected from highdensity polypropylene, low density polypropylene, or combinationsthereof.
 16. The formulation of claim 1, wherein the formulation isconfigured for manufacturing of alternative construction systems forbuildings, facilities, shelters, accessories, and housing productsincluding partitions, pavers, pillars, fence-posts, tablets, bricks,baffles, window frames, blocks, floors, pavements, or any otherconstruction object.
 17. The formulation of claim 1, wherein theformulation is configured for a construction system for buildings,facilities, accessories, and products with architectural elements notrequiring maintenance, and having outdoor durability, resistance tohumidity, immunity to insects, immunity to rodents, immunity tomicroorganisms; and anticorrosive properties, decomposition proof,thermal isolating, acoustic isolating, electric isolating, impactresistant, traction and bending resistant, fireproof, and eco-friendlyproperties.
 18. The formulation of claim 17, wherein the architecturalelements are configured for easy and fast installation, ease offabrication, in which the element can be cut, drilled, nailed orpierced, and be plastered, painted, or plated.
 19. An architecturalpiece that is manufactured with recycled plastic formulation, thatcomprises: a. polyethylene; b. Acrylonitrile Butadiene Styrene (ABS); c.calcium carbonate; d. polypropylene, wherein the polyethylene is in anamount in the range from 3 to 39% wt., based on the total weight of theformulation; the ABS is in an amount in the range from 16 to 18% wt.,based on the total weight of the formulation; the calcium carbonate isin an amount in the range from 18 to 20% wt., based on the total weightof the formulation; and the polypropylene is in an amount in the rangefrom 20 to 24% in weight, based on the total weight of the formulation.20. The architectural piece of claim 19, wherein the architectural piececomprises one or more plastic blocks.
 21. The architectural piece ofclaim 20, wherein the plastic blocks comprise four basic elements. 22.The architectural piece of claim 21, wherein the four basic elements areassembled in a one-way direction with a male and female system.
 23. Thearchitectural piece of claim 22, wherein the male side comprises theupper and side slip-on connectors.
 24. The architectural piece of claim23, wherein the female side comprises the bottom and side wings.
 25. Thearchitectural piece of claim 19, wherein the male dimensions are 0.50meters (m) (1.64 feet) long, 0.10 m (0.32 feet) high, with a slip-onconnector that is 0.03 m (0.098 feet) long, 0.10 m (0.32 feet) high, and0.03 m (0.098 feet) wide; the female dimensions are 0.47 meters m (1.54feet) long, 0.10 m (0.32 feet) high, with a slip-on connector that is0.03 m long, 0.10 m (0.32 feet) high and 0.02 m (0.065 feet) wide. 26.The architectural piece of claim 19, wherein the male dimensions are0.25 meters (m) (0.82 feet) long, 0.10 m (0.32 feet) high, with aslip-on connector that is 0.03 m (0.098 feet) long, 0.10 m (0.32 feet)high, and 0.03 m (0.098 feet) wide; the female dimensions are 0.22meters m (0.72 feet) long, 0.10 m (0.32 feet) high, with a slip-onconnector that is 0.03 m (0.098 feet) long, 0.10 m (0.32 feet) high, and0.02 m (0.065 feet) wide.
 27. The architectural piece of claim 20,wherein the architectural piece further comprises from one to fourvertical openings or holes.
 28. The architectural piece of claim 20,wherein the plastic blocks are assembled without mortar, additives,sealants, or adhesives.
 29. The architectural piece of claim 19, whereinit comprises Jamb
 1. 30. The architectural piece of claim 29, whereinthe Jamb 1 is used as a window connector.
 31. The architectural piece ofclaim 30, wherein the Jamb 1 is used as a window connector, where thetop slip-on connector of the blocks rests.
 32. The architectural pieceof claim 30, wherein it has a slot or guide.
 33. The architectural pieceof claim 30, wherein the slot or guide also connects walls, windows, anddoor openings.
 34. The architectural piece of claim 19, wherein the Jamb1 has dimensions that are 2.20 m (7.21 feet) long, 0.10 m (0.32 feet)high.
 35. The architectural piece of claim 19, wherein it comprises aJamb
 2. 36. The architectural piece of claim 35, wherein it has twoslots or guides.
 37. The architectural piece of claim 36, wherein a Jamb2 works as a base for the beginning of the construction of a wall. 38.The architectural piece of claim 35, wherein the Jamb 2 has dimensionsthat are 2.20 m (7.21 feet) long, 0.10 m (0.32 feet) high.
 39. Thearchitectural piece of claim 19, wherein the plastic blocks can beassembled to form a partition unit joined to a structural column. 40.The architectural piece of claim 19, wherein the plastic blocks orpavers are suitable for floor and pavement construction for lightvehicular and pedestrian traffic.
 41. The architectural piece of claim40, wherein the plastic blocks or pavers may be smooth or may havedifferent tactile finishes on their exposed face, grids, cylinders,guides, lines, and any other geometric or non-geometric shape.
 42. Thearchitectural piece of claim 40, wherein the plastic blocks or pavershave dimensions of 0.40 m (1.31 feet) long, 0.40 m (1.31 feet) wide, and0.05 m (0.16 feet) high.
 43. The architectural piece of claim 40,wherein the plastic blocks or pavers may be rectangular, circular,triangular, hexagonal, pentagonal, and any and other geometric shape.44. The architectural piece of claim 19, wherein the architectural pieceis configured alternative construction systems for buildings,facilities, shelters, accessories, and housing products such as dividingwalls, pavers, pillars, fence-posts, tablets, bricks, baffles, windowframes, blocks, floors, pavement, or any other construction object. 45.The architectural piece of claim 19, wherein the architectural piece isresistant to the outdoors, resistant to humidity, immune to insects,immune to rodents, immune to microorganisms, anticorrosive,decomposition proof, thermal isolating, acoustic isolating, electricisolating, impact resistant, traction resistant, and bending resistant,fireproof, and eco-friendly.
 46. The architectural piece of claim 19,wherein the architectural piece is configured for easy assembly andmanufactured with recycled or recovered plastic that does not requiremaintenance, having an easy and fast installation, ease of fabrication,it can be cut, drilled, nailed or pierced, and be plastered, painted, orplated.
 47. The architectural piece of claim 19, wherein thearchitectural piece does not require maintenance, does not requireskilled workforce for its construction.